Package and heat sealing device

ABSTRACT

Aspects of the present invention are directed to a heat sealed packaging wherein the heat seal is along a curved surface. Additional aspects of the present invention are directed to a device for heat sealing a package on a surface that is curved along the direction of force.

TECHNOLOGY FIELD

Aspects of the present invention are directed to a heat sealed packageand device for heat sealing a package, and in particular, a package heatsealed along a non planer surface and a device for providing a heat sealon a curved surface.

BACKGROUND

Tamper resistant packaging is a high priority for many consumer productcompanies, and, in particular, consumer healthcare product companieswhere the contents of the package may be dangerous if contaminated priorto purchasing or if consumed by a minor without the supervision of anadult. Traditionally, heat sealed packaging has been known to be a verysecure and tamper resistant format.

A clamshell is a one-piece container consisting of two halves joined bya hinge area which allows the structure to come together to close.Clamshells are often made of a shaped plastic material, in a way that issimilar to a blister pack. Clamshell containers can be made of a varietyof plastics such as polystyrene, polyester, PVC, among others. Thematerial can be made by thermoforming or can be injection molded intothe desired shapes. A single piece of material is used for the top andbottom with a “living hinge” that is integral with the material, ratherthan added separately. Clamshells can use a variety of means of closingor sealing. Some have self-locking tabs, snaps, or have a friction fit.Others use adhesive, pressure-sensitive tape, labels, staples, or areheat sealed, rf sealed, or ultrasonic sealed.

Heat sealing is the process of sealing one thermoplastic to anothersimilar thermoplastic using heat and pressure. The direct contact methodof heat sealing utilizes a constantly heated die or sealing bar to applyheat to a specific contact area or path to seal or weld thethermoplastics together.

The concept of heat sealing is well known in the art. Traditionally,heat sealing has required that the surfaces to be sealed be linear aboutthe directional force (i.e. a flat surface). This provides limitationsto the use of heat sealing on packaging that is more contoured andappealing to the consumer. For such complex packaging, other sealingmethods are required that may not provide the tamper resistance andsecurity that heat sealing provides, thus resulting in a conumdrum for acompany seeking high tamper resistance while also seeking appealingpackaging to consumer. Thus, technology allowing for heat sealing on aundulating or curved surface is highly desirable.

SUMMARY

Aspects of the present invention are related to a device for heatsealing a package comprising: a support boss plate having a boss. Theboss has a face with one more cavities for receiving a package and oneor more gaskets secured to the face and surrounding at least a portionof the one or more cavities. The gaskets and at least the portion of theface on which the one or more gaskets is secured is non-flat. The devicefurther includes a heater plate having a heater with a face and one ormore heating flanges mateable with the one or more gaskets on thesupport boss. The heating flanges are be non-flat. Upon mating of thesupport boss with the heater and an application of a downwarddirectional force and heat, a package may be sealed with a non-linearseal along the downward directional force.

The support boss plate and the heater plate may further shut heightbosses for optimizing the distance between the support boss and theheater when the support boss and heater are mated. The one or moregaskets may have a width of between about 0.05 mm and about 0.5 mm, orbetween about 0.125 mm and about 0.25 mm. The one or more heatingflangse may have a width of 0.05 mm and about 0.5 mm, or about 0.125 mmand about 0.25 mm.

In certain embodiments, the support boss plate and the heater boss platecomprise multiple bosses and multiple heaters corresponding to themultiple bosses. The multiple bosses may be independently adjustableabout the x, y, and z axis.

An additional aspect of the present invention is related to a packagefor holding a product comprising: a first side having an optional firstrecessed area and a first perimeter edge wherein at least a portion ofthe first perimeter edge is curved and a second side having a secondrecessed area and a second perimeter edge wherein at least a portion ofthe second perimeter edge is curved. The first side and the second sideare heat sealed together along at least a portion of the first perimeteredge and at least a portion of the second perimeter edge.

The package may be comprised of PET-G, PVC, or polystyrene. In certainembodiments, the packaged is comprised of PET-G. The package may furthercomprise a consumer product within the package, such as, for example, aconsumer healthcare product.

In another embodiment, the package for holding a product furthercomprises an interior wall curved out of plane and wherein the secondside further comprises an interior wall curved out of plane, wherein theinterior walls are heat sealed together to form at least twocompartments.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a perspective view of an exemplary package prior to heatsealing;

FIG. 2 shows a perspective view of an exemplary heat sealed package ofthe present invention;

FIG. 3 shows a right side view of an exemplary heat sealed package ofthe present invention;

FIG. 4 shows a left side view of an exemplary heat sealed package of thepresent invention;

FIG. 5 shows a perspective view of an exemplary support boss plate;

FIG. 6 shows a top view of an exemplary support boss plate;

FIG. 7 shows a side view of an exemplary support boss plate;

FIG. 8 shows a top view of an exemplary individual support boss;

FIG. 9 shows a side view of an exemplary individual support boss;

FIG. 10 shows a perspective view of an exemplary heater plate;

FIG. 11 shows a top view of an exemplary heater plate;

FIG. 12 shows a side view of an exemplary heater plate;

FIG. 13 shows a top view of an exemplary individual heater;

FIG. 14 shows a side view of an exemplary individual heater;

FIG. 15 shows a side view of an exemplary support boss plate and anexemplary heater plate during sealing;

FIG. 16 shows a side view of an exemplary individual heater and anexemplary support boss during sealing;

FIGS. 17A-E show an exemplary process for heat sealing a packaging;

FIG. 18 shows a perspective view of an exemplary package having multiplecompartments prior to heat sealing;

FIG. 19 shows a perspective view of an exemplary heat sealed packagehaving multiple compartments;

FIG. 20 shows a side view of an exemplary heat sealed package havingmultiple compartments;

FIG. 21 shows a top view of an exemplary individual support boss forsealing a package having multiple compartments;

FIG. 22 shows a side view of an exemplary individual support boss forsealing a package having multiple compartments;

FIG. 23 shows a top view of an exemplary individual heater for sealing apackage having multiple compartments;

FIG. 24 shows a side view of an exemplary individual heater for sealinga package having multiple compartments; and

FIG. 25 shows a side view of an exemplary individual heater and anexemplary support boss during sealing a package having multiplecompartments.

DETAILED DESCRIPTION

Aspects of the present invention are directed to a package having afirst side with an optional recessed portion and a perimeter edge and asecond side with a recessed portion and a perimeter edge wherein atleast a portion of the seal surface of each side is non planer. Thepackage is sealed by heat sealing at least a portion of the each of theperimeter edges together. The ability to heat seal non planer edges of apackage provides for the ability to provide a highly tamper resistantpackage that is also a complex design and visually appealing toconsumers.

In some embodiments, the package may include one side that does notinclude a recessed portion, i.e., a flat surface, that is can be heatsealed to a side with a recessed portion to form an enclosed package. Insome embodiments, the package may be a clamshell package, i.e., thefirst side and second side joined by an integral hinge.

The package may be comprised of one or a combination of any materialsuitable for heat sealing. Sutiable materials may be, for example,polystyrene, polyester, polyvinylchloride (PVC), polyethyleneterephthalate (PET), or polyethylene terephthalate glycol-modified(PET-G). In a particular embodiment, the material may be PET-G, PVC, ormore particularly, the material may be PET-G. In some embodiments, thefirst side and the second side of the package may be comprised of thesame material. In other embodiments, the first side and second side maybe comprised of different materials.

The package may contain various products, such as for example consumerproducts or more particularly consumer healthcare products. Examplaryconsumer healthcare products include dermatological products, weightloss products, oral healthcare products, cold and flu products,respiratory products, analgesics, vitamins and minerals,gastrointestinal products, nicotine replacement therapy products,nutritional products, and pain relief products, among others.

To provide the most visual appeal to the consumer, the region of thepackage that is heat sealed is minimally noticeable to the consumer. Assuch a narrow heat seal is preferred, such as, for example a heat sealhaving a width of between about 1 mm and about 20 mm, more preferablybetween about 3 mm and about 6 mm. A narrow heat seal also provides forthe edge of the package to be as small as possible, allowing for thepackage to “stand alone” on a display shelf.

FIG. 1 shows a perspective view of an exemplary package 300 prior tosealing. Package 300 includes first side 310 and second side 350. Firstside 310 includes top 311, recessed portion, 315, first side firstcurved side edge 312, first side second curved side edge 313, and firstside front edge 314. Second side 350 inclues second side first curvedside edge 351, second side second curved side edge 352, second sidefront edge 353, second side wall 354 and second side cavity 355. Firstside 310 and second side 350 are connected at integral hinge 340.

FIG. 2 shows a perspective view of an exemplary package 300A that hasbeen heat sealed. First side first curved side edge 312 and second sidefirst curved side edge 351 have been sealed at heat seal 330. First sidesecond curved side edge 313 and second side second curved side edge 352have been sealed at heat seal 330. First side front edge 314 and secondside front edge 353 have also been sealed at heat seal 330.

Aspects of the present invention are directed to a device for heatsealing a package wherein the heat sealing is performed on a surfacecurved along the downward directional force of the heat sealing device.Heat sealing in such a manner provides for the heat sealing of moreintricate and appealing packages while also providing a highly tamperresistant package. A device of the present invention includes a supportboss plate and a heater plate. These plates may be attached to machinerygenerally known by those skilled in the art for heat sealing packages.

An exemplary support boss plate 100 is shown in FIGS. 5, 6, and 7.Support boss plate 100 includes support plate 101 into which individualbosses 110 are located. Bosses 110 are adjustable along the X, Y, and Zaxis to allow for proper alignment with heater plate 200. Support bossplate 100 has length L1 and width W1. Length L1 side includes shutheight bosses 120 for optimizing the space between support boss 110 andheaters 210. Length L1 side includes fastener 132 with hole 130 formating with a corresponding faster on heater plate 200. Width W1 sideincludes faster 133 with hole 131 for mating with corresponding fasteneron heater plate 200.

An exemplary individual support boss is shown in FIGS. 8 and 9. Boss 110includes perimeter wall 113, cavity 111 for receiving a side of apackage and gasket 112 about perimeter wall top 114.

An exemplary heater plate is shown in FIGS. 10, 11, and 12. Heater plate200 includes mounting plate 201 onto which individual heaters 210 arelocated. Heater plate 200 has length L2 and width W2. Length L2 sideincludes shut height bosses 220 corresponding to support boss plate 100shut bosses 120 for optimizing the space between bosses 110 and heaters210. Length L2 side includes fastener 232 with post 231 for mating witha corresponding fastener 132 with hole 131 on support boss plate 100.Width W2 side includes fastener 232 with post 230 for mating withcorresponding fastener 133 and hole 131 on support boss plate 100.

An exemplary individual heater is shown in FIGS. 13 and 14. Heater 210includes base 211, side wall 213 defining cavity 214. Heater flange 212surrounds at least a portion of base 211 and is on top of side wall 213.

FIG. 15 shows a side view of support boss plate 100 and heater plate 200in contact during the heat sealing process. Corresponding shut bosses120 and 220 are in contact with each other. Support boss plate 100 andheater plate 200 are secured by fasteners 133 and 232. First side secondcurved egde 311 and second side second curved edge 351 are in contactwith each other through the application of pressure and heat from flange212 of heater 200 and gasket 112 of boss. Upon the application ofpressure and heat, first side second curved edge 311 and second sidesecond curved edge 351 will be heat sealed 330. FIG. 16 shows a sideview of an individual boss 110 and heater 210 during sealing first sidesecond curved egde 311 and second side second curved edge 351 throughthe application of pressure and heat from flange 212 of heater 200 andgasket 112 of boss.

One skilled in the art would understand that the support boss plates andheater plates of the present invention may be attached to machinery forproviding heat to the heater plate and moving the plates together toseal packages at suitable pressures.

Aspects of the present invention are also directed to heat sealedpackages wherein the heat seal is applied to a curved peripheral edge aswell as a curved interior surface. In some embodiments the heat sealedinterior surface may act to divide the packaging into multiplecompartments. These multiple compartments may contain multiple products.The products may be the same product, or different products, such as forexample, complimentary products that may be used together.

FIG. 18 shows a perspective view of an exemplary package 500 prior tosealing. Package 500 includes first side 510 and second side 550. Firstside 510 includes top 511, recessed portion, 315, first curved side edge512, second curved side edge 513, and front edge 514. Second side 550inclues first curved side edge 551, second curved side edge 552, frontedge 553, second side wall 554, interior curved wall 556 with interiorcurved wall edge 557, and 2 second second side cavities 555A and 555B.First side 510 and second side 550 are connected at integral hinge 540.

FIG. 19 shows a perspective view of an exemplary package 500A that hasbeen heat sealed. First side first curved side edge 512 and second sidefirst curved side edge 551 have been sealed at heat seal 530. First sidesecond curved side edge 513 and second side second curved side edge 552have been sealed at heat seal 530. First side front edge 514 and secondside front edge 553 have also been sealed at heat seal 530. First sidetop 510 has also been heat sealed to interior curved wall edge 557.

An exemplary individual support boss is shown in FIGS. 21 and 22. Boss610 includes perimeter wall 613, cavities 611A and 611B separated byboss interior curved wall 615 with boss interior curved wall gasket 616for receiving a side of a package and gasket 612 about perimeter walltop 614.

An exemplary individual heater is shown in FIGS. 23 and 24. Heater 710includes base 711, side wall 713 defining cavities 714A and 714B. Heaterflange 712 surrounds at least a portion of base 711 and is on top ofside wall 713. Curved interior heater flange 715 at least partiallyseparates cavities 714A and 714B and rests on top of curved interiorheater wall 716.

FIG. 25 shows a side view of an individual boss 610 and heater 710during sealing first side second curved egde 511 and second side secondcurved edge 551 through the application of pressure and heat from flange712 of heater 700 and gasket 612 of boss.

Suitable temperatures applied to the surface to be heat sealed may bebetween about 390° F. and about 500° F., or between about 415° F. andabout 450° F.

Suitable pressure applied to the surface to be heat sealed may bebetween about 40 psi and about 110 psi, or between about 80 psi andabout 100 psi.

An additional aspect of the present invention is directed to a method ofheat sealing a package. FIG. 17 shows an exemplary process for heatsealing a package. A package as described herein may be placed into acavity of a boss as described herein (FIG. 17A). The package may beclosed (FIG. 17B). The heater may then be lowered onto the boss, and aheat and pressure may be applied to the edge of the package (FIG. 17C)to form a heat seal. Suitable temperatures and pressures are disclosedherein. The heater may be removed (FIG. 17D) and the sealed packagedremoved from the boss (FIG. 17E).

What is claimed is:
 1. A device for heat sealing a package comprising: asupport boss plate having a boss with a face with one or more cavitiesfor receiving a package and one or more gaskets secured to the face andsurrounding at least a portion of the one or more cavities, wherein thegasket and at least the portion of the face on which the one or moregaskets is secured is non-flat, and a heater plate having a heater witha face and one or more heating flanges mateable with the one or moregaskets on the support boss, wherein the one or more heating flanges arenon-flat; wherein upon mating of the support boss with the heater and anapplication of a downward directional force and heat, a package may besealed with a non-linear seal along the downward directional force. 2.The device of claim 1, wherein the support boss plate and the heaterplate further include shut height bosses for optimizing the distancebetween the support boss and the heater when the support boss and heaterare mated.
 3. The device of claim 1, wherein the one or more gaskets hasa width of between about 0.05 mm and about 0.5 mm.
 4. The device ofclaim 1, wherein the one or more gaskets has a width of between about0.125 mm and about 0.25 mm.
 5. The device of claim 1, wherein the one ormore heating flanges has a width of 0.05 mm and about 0.5 mm.
 6. Thedevice of claim 5, wherein the one or more heating flanges has a widthof about 0.125 mm and about 0.25 mm.
 7. The device of claim 1, whereinthe support boss plate and the heater boss plate comprise multiplebosses and multiple heaters corresponding to the multiple bosses.
 8. Thedevice of claim 7, wherein the multiple bosses are independentlyadjustable about the x, y, and z axis.
 9. A package for holding aproduct comprising: a first side having an optional first recessed areaand a first perimeter edge wherein at least a portion of the firstperimeter edge is curved out of plane; a second side having a secondrecessed area and a second perimeter edge wherein at least a portion ofthe second perimeter edge is curved out of plane; wherein the first sideand the second side are heat sealed together along at least a portion ofthe first perimeter edge and at least a portion of the second perimeteredge to form a compartment.
 10. The package of claim 9, wherein thepackage is comprised of PET-G, PVC, or polystyrene.
 11. The package ofclaim 10, wherein the material is PET-G.
 12. The package of claim 9,further comprising a consumer product within the package.
 13. Thepackage of claim 12, wherein the consumer product is a consumerhealthcare product.
 14. The package of claim 9, wherein the first sidefurther comprises an interior wall curved out of plane and wherein thesecond side further comprises an interior wall curved out of plane,wherein the interior walls are heat sealed together to form at least twocompartments.